US8358033B2 - Systems, methods, and apparatus for converting DC power to AC power - Google Patents

Systems, methods, and apparatus for converting DC power to AC power Download PDF

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US8358033B2
US8358033B2 US12/505,858 US50585809A US8358033B2 US 8358033 B2 US8358033 B2 US 8358033B2 US 50585809 A US50585809 A US 50585809A US 8358033 B2 US8358033 B2 US 8358033B2
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power
converter
source
ground
inverter
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US20100277001A1 (en
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Robert Gregory Wagoner
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GE Grid Solutions LLC
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General Electric Co
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Assigned to GENERAL ELECTRIC COMPANY reassignment GENERAL ELECTRIC COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: WAGONER, ROBERT GREGORY
Priority to AU2010202922A priority patent/AU2010202922A1/en
Priority to EP20100169390 priority patent/EP2278697A1/en
Priority to CN2010102408591A priority patent/CN101958658A/zh
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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J3/00—Circuit arrangements for ac mains or ac distribution networks
    • H02J3/38—Arrangements for parallely feeding a single network by two or more generators, converters or transformers
    • H02J3/381—Dispersed generators
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J2300/00—Systems for supplying or distributing electric power characterised by decentralized, dispersed, or local generation
    • H02J2300/20—The dispersed energy generation being of renewable origin
    • H02J2300/22—The renewable source being solar energy
    • H02J2300/24—The renewable source being solar energy of photovoltaic origin
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy
    • Y02E10/56—Power conversion systems, e.g. maximum power point trackers

Definitions

  • the invention relates to power conversion, and more specifically, to systems, methods, and an apparatus for converting direct current (DC) power to alternating current (AC) power.
  • DC direct current
  • AC alternating current
  • a direct current (DC) power source such as a fuel cell or photovoltaic cell, typically produces a low voltage at a high current. While these DC power sources provide a source of power, the power can be inconsistent, varying with local operating conditions. For example, in the case of a photovoltaic cell, the power output can vary according to the amount of direct sunlight available at the face of the cell and the physical condition of the cell. Many power applications require a more stable source of power than these DC power sources can provide. Moreover, many power applications require alternating current (AC) power and not DC power to operate. Thus, it is generally necessary to convert the variable DC power provided by the DC power source to a stable source of AC power. Conventional systems have been adapted for such power conversion, but conventional systems can be costly and inefficient.
  • solar arrays comprise many photovoltaic cells and are often spread across many acres of land.
  • conventional systems rely on various gauges of wiring, oftentimes in relatively great lengths. This wiring can be relatively bulky and expensive, making implementation costly and cumbersome.
  • conventional systems can not accommodate for failures or fluctuations in individual cells. That is, because individual cells or arrays can not be adjusted individually to their maximum power point, when one cell fails, the total power output of the conventional system diminishes.
  • Certain embodiments of the invention can address some or all of the needs described above. Certain embodiments of the invention are directed to systems, methods, and an apparatus for converting direct current (DC) power to alternating current (AC) power.
  • a method for converting DC power to AC power can be provided. The method can begin with providing DC power from at least one DC power source, wherein the DC power source can be associated with a first ground. The method can continue with conditioning the DC power provided by the DC power source and isolating the conditioned DC power from the first ground. The method can proceed by converting the conditioned DC power to AC power so that the AC power, being isolated from the first ground, can be referenced to a second ground. The method can also include providing the converted AC power to at least one load.
  • a system for converting DC power to AC power can be provided.
  • the system can include at least one DC power source associated with a first ground electrically coupled to at least one DC-to-DC converter.
  • the DC-to-DC converter can be operable to condition the DC power provided by the DC power source and to isolate the conditioned DC power from the first ground.
  • the system can also include at least one inverter electrically coupled to the DC-to-DC converter.
  • the inverter can be operable to convert the conditioned DC power to AC power, wherein the converted AC power can be associated with a second ground.
  • the system can also include at least one load for receiving the converted AC power.
  • an apparatus for converting DC power to AC power can be provided.
  • the apparatus can include a DC-to-DC converter electrically coupled to a source of DC power and operable to condition the DC power provided by the source of DC power and to isolate the conditioned DC power from a first ground associated with the source of DC power.
  • the apparatus can also include an inverter electrically coupled to the DC-to-DC converter. The inverter can be operable to convert the DC power provided by the DC-to-DC converter to AC power associated with a second ground.
  • FIG. 1 illustrates a conventional system for converting direct current (DC) power to alternating current (AC) power.
  • FIG. 2 illustrates a exemplary system and apparatus for converting DC power to AC power according to one embodiment of the invention.
  • FIG. 3 illustrates a chart displaying an exemplary maximum power point for a DC power source according to one embodiment of the invention.
  • FIG. 4 illustrates an exemplary method for converting DC power to AC power according to one embodiment of the invention.
  • FIG. 1 illustrates a conventional DC-to-AC power conversion system 100 for converting direct current (DC) power to alternating current (AC) power.
  • conventional power conversion system 100 one or more solar array sections 105 A-N can provide a source of DC power.
  • the solar array sections 105 A-N can be a linked collection of photovoltaic cells, which convert solar energy into DC power via a photovoltaic effect. Because the power produced by any individual cell is relatively low, photovoltaic cells can be linked together in series and/or parallel combinations to form an array so that the power from individual photovoltaic cells can be combined.
  • DC power sources can tap into an almost inexhaustible source of energy
  • DC power sources do have shortcomings.
  • One shortcoming is that the DC power output of such cells can be influenced by local conditions—such as temperature and the condition of the cells—making their power output variable.
  • a second shortcoming is that photovoltaic cells and fuel cells provide a source of DC power, whereas most electric power loads require alternating current (AC) type power, meaning that DC power sources can not be directly connected to utility power grid 110 for general power purposes.
  • AC alternating current
  • the combination of their variable power output and the fact that their power output is DC-type power means that to incorporate DC power sources, like photovoltaic cells and fuel cells, into the utility power grid 110 illustrated in FIG. 1 , their DC power outputs must be converted, such as by electrically coupling the solar array sections 105 A-N to a power converter such as power converter 115 .
  • Power converter 115 can convert the electrical energy from a DC power source, such as solar array sections 105 A-N, to a relatively stable and reliable AC power source.
  • Power converter system 115 can include DC-to-DC converter 120 .
  • DC-to-DC converter 120 is electrically coupled to solar array sections 105 A-N in parallel and operable to condition the DC power provided from these sources to make the DC power more stable.
  • DC-to-DC converter 120 provides regulated DC power, but not AC power
  • an inverter can convert the regulated DC power to AC power.
  • power converter system 115 can include a DC-to-AC inverter 125 to convert the regulated DC power produced by DC-to-DC converter 120 into AC power, such as a 60 Hz sinusoidal current waveform, which can be provided to the utility grid 110 .
  • Interfacing power converter system 115 with utility power grid 110 can require an isolation transformer 130 .
  • Isolation transformer 130 isolates solar array sections 105 A-N, which are referenced to a first ground like an earth ground, from the utility power grid 110 , which can be referenced to a second ground and not common with the first ground.
  • a relatively low frequency isolation transformer 150 is electrically connected between the DC-to-AC inverter 125 and a designated load, such as utility power grid 110 .
  • Such low frequency transformers like isolation transformer 130 can be quite costly and relatively large in size. Thus, in conventional system 100 , a large physical footprint is required and significant costs must be incurred to implement the system.
  • DC-to-DC converter 120 can be electrically coupled with multiple solar arrays 105 A-N in parallel. In making this parallel electrical combination, the DC power provided by any one solar array section 105 A can be combined with the DC power provided by other solar array sections 105 B-N.
  • This parallel connection can be made with various gauges of electrical wiring 121 .
  • relatively small wiring such as wiring used to conduct about 1 amp to about 10 amps of current, can electrically couple the farthest solar array to the next closest array.
  • the wire required to couple the multiple solar arrays 105 A-N must be of a larger and larger gauge to accommodate the increased current supply.
  • electrical wiring 121 can comprise 100 amps and even 1000 amps capacities.
  • DC-to-DC converter 120 In conventional systems, the relatively large physical footprint of DC-to-DC converter 120 results in DC-to-DC converter 120 being located remotely from solar arrays 105 A-N. In making this remote electrical connection, a substantial length of wiring may be required. In addition, to accommodate the parallel electrical combination of solar arrays 105 A-N, a large amount of wiring of various gauges can be required, which can increase the costs associated with wiring 121 . Furthermore, because multiple solar arrays 105 A-N are electrically coupled to one or only a few power converters 115 , it can be relatively difficult to operate or adjust the power output of any single array 105 A. When one solar array section such as 105 A fails, the power output of conventional system 100 can suffer because the solar array sections 105 A-N can not be operated independently of each other. It is sometimes desirable to reduce these costs and inefficiencies associated with conventional system 100 .
  • FIG. 2 illustrates an exemplary system 200 and apparatus for converting DC power to AC power according to one embodiment of the invention.
  • exemplary power supply system 200 can include a DC power sources 205 A-N, such as a photovoltaic cell, a fuel cell, an array of such cells, a battery, or the like.
  • the DC power source can be one or more solar array sections 205 A-N similar to 105 A-N in FIG. 1 .
  • exemplary power supply system 200 can electrically couple solar array sections 205 A-N to a load, such as by incorporation into the utility power grid 220 .
  • exemplary power supply system 200 can reduce the need for the relatively large low frequency isolation transformer 130 of FIG. 1 by replacing the low frequency isolation transformer 130 with an isolation transformer in each converter, as shown at 220 A.
  • an apparatus such as converter 220 A can condition the DC power provided by solar array section 205 A and isolate the DC power solar array section 205 A provides, which can be referenced to a first ground such as an earth ground, from the utility power grid 210 , which can be referenced to a second ground, such as an AC ground.
  • converter 220 A can stabilize the DC power being provided.
  • converter 220 A can include the use of a switching type regulator that can regulate the DC voltage at some level using a form of pulse width modulation control.
  • converter 220 A can include a boost converter, or step up converter, that is operable to boost the DC power provided by solar array section 205 A from a first voltage to a second voltage.
  • converter 220 A can be operable to receive an unstable 300 Volt DC power signal from solar array section 205 A, to condition the unstable signal so that it can be a 300 Volt regulated DC power signal, and to boost the 300 Volt regulated DC power signal to a 600 Volt regulated DC power signal at the output of converter 205 .
  • the isolation transformer within converter 220 A can be adapted to operate at high frequencies.
  • relatively smaller and lower cost components can be used, which is at least one technical effect of the invention. More specifically, because a transformer's cost and weight can be inversely proportional to the operating frequency of the transformer, for a given output power, increasing the operating frequency can result in a relatively smaller transformer. For example, a transformer designed for about 400 Hz may be roughly five times smaller in volume, cost, and weight when compared to an isolation transformer with similar power rating that operates at 50/60 Hz.
  • an apparatus such as converter 220 A can include the use of a switching type regulator operating at approximately 3 kHz.
  • the isolation transformer can be scaled to operate at approximately 3 kHz as well. Scaling the isolation transformer in this way means that the size and cost of the 3 kHz isolation transformer within converter 220 A may be a relatively small fraction of the size and cost of the 50/60 Hz isolation transformer 130 in FIG. 1 .
  • the isolation transformer to be part of converter 220 A can be scaled to operate at a frequency in the range of approximately 50 Hz to 500 kHz.
  • converter 220 A and its associated isolation transformer can accommodate relatively smaller components by operating at high frequencies, converter 220 A can maintain a relatively smaller physical footprint.
  • converter 220 A can be relocated to be physically nearer to an associated solar array section such as 205 A.
  • the DC power source comprises a solar array physically located across a relatively broad expanse of real estate
  • multiple converters 220 A-N can be used and adapted to electrically couple to individual cells or portions of the solar array.
  • Converters 220 A-N can then be electrically coupled in parallel to DC-to-AC inverter 225 via wiring 226 .
  • each converter 220 is electrically connected to a DC power source like solar array sections 205 A-N
  • the flexibility and total power output of system 200 can be improved.
  • three converters 220 A, 220 B, and 220 N are illustrated as being electrically connected in series with a solar array sections 205 A, 205 B, and 205 N, and electrically connected in parallel with DC-to-AC inverter 225 . It will be appreciated that in other embodiments, more converters 220 A-N and solar arrays 205 A-N can be used.
  • using multiple converters 220 A-N electrically coupled to solar array sections 205 A-N and in parallel with DC-to-AC inverter 225 can enable the relatively quick repair of the total solar array. For instance, if solar array section 205 A fails, only the parallel branch of system 200 associated with the failed section need be deactivated for repair. In conventional system 100 , when one solar array section 105 A fails, the whole solar array comprising multiple solar array sections 105 A-N requires deactivation for repair since the whole solar array is electrically coupled in parallel with power converter 115 .
  • MPPT Maximum Power Point Tracking
  • solar array sections 205 A-N which can be part of a much larger solar array, can allow for optimization of the available solar energy from the larger solar array as a whole, such as through compensation for shadowing or for weak or broken sections of the array.
  • the voltage, current, and power produced by various DC power sources can vary according to ambient conditions.
  • the electrical response of DC power sources can also depend on the electrical impedance of the load electrically coupled to the DC power source. This variability is illustrated in FIG. 3 , where exemplary charts 300 and 350 are illustrated for solar array section 105 .
  • Chart 300 illustrates an exemplary current-voltage (I-V) curve for solar array section 205 A at a particular radiance and operating temperature.
  • Chart 350 illustrates a corresponding current-power (I-P) chart.
  • solar array section 205 A produces its maximum current when there is no resistance in the circuit, that is, when the load comprises zero impedance.
  • the voltage provided by solar array section 205 A is zero, as is solar array section 205 A's DC power output at 355 .
  • solar array section 205 A produces its maximum voltage when there is infinite resistance in the circuit, that is, when the load comprises a very large impedance.
  • the current provided by solar array section 205 A is zero, as is the DC power output at 360 .
  • solar array section 205 A can exhibit the electrical response illustrated by the curve in chart 300 at a particular radiance and operating temperature. As illustrated in chart 350 , the power available from solar array section 205 A at any point along the curve illustrated in chart 300 is the product of current and voltage at that point. At any particular temperature and radiance, solar array section 205 A has an operating point 365 that results in a maximum power output. In other words, at any particular temperature and radiance, solar array section 205 A can be characterized by a load impedance as shown at point 315 that results in the maximum power transfer to a load.
  • methods for MPPT can be embodied in an electronic system that can operate solar array section 205 A, or other DC power source, in a manner that allows solar array section 205 A to produce its maximum power.
  • an electronic system can include controller 230 A.
  • Controller 230 A can be adapted to control the operating characteristics of converter 220 A.
  • controller 230 A can control certain characteristics of converter 220 A to cause its input impedance, as experienced by solar array section 205 A, to vary. With this varying impedance, the power provided by solar array section 205 A will also vary until the load impedance provided by converter 220 A to solar array section 205 A corresponds to the maximum power point.
  • controller 230 A can provide MPPT optimization. While only one method is presented here and is associated with modifying certain characteristics of converter 220 A, many other methods can be employed in accordance with the teachings of the present invention.
  • Controller 230 A can be implemented using hardware, software, or a combination thereof for performing the functions described herein.
  • controller 230 A can be a processor, an ASIC, a comparator, a differential module, or other hardware means.
  • Controller 230 A can also comprise software or other computer-executable instructions that may be stored in a memory and may be executable by a processor or other processing means.
  • controllers 230 A-N the maximum power point for each solar array section 205 A-N can be obtained.
  • the power output of the entire solar array which can comprise multiple solar array sections 205 A-N, can be optimized.
  • optimization at the level of each solar array section 105 A-N is not obtainable.
  • conventional converter 115 in system 100 is connected in parallel to a plurality of solar array sections 105 , conventional converter 115 can not vary the load impedance provided to individual solar array sections 105 so that the maximum power transfer point for individual sections can be obtained.
  • conventional system 100 can only provide a single MPPT setpoint for the plurality of solar array sections 105 A-N.
  • a plurality of MPPT setpoints can be provided individually to the plurality of solar array sections 205 A-N.
  • the overall utilization and power output of system 200 can be optimized.
  • converters 220 A-N can accommodate a smaller power rating. This is partly because a higher voltage and lower current is provided to converters 220 A-N when compared to the voltage and current being provided to conventional converter 115 in FIG. 1 .
  • smaller gauge wiring can also be used to electrically couple converters 220 A-N to DC-to-AC inverter 225 , which can also increase the efficiency of system 200 .
  • the wiring 121 between the solar array sections 105 A-N and the DC-to-DC converter 120 can be both lengthy and expensive.
  • the output voltage can drop as the output current increases, meaning that the expensive wiring 121 , which is expensive partially because of its large gauge, may not be used at its maximum potential.
  • 600 Volt wire can be used to accommodate the maximum output of the multiple parallel-connected solar array sections 105 A-N, but at any given point in time, solar array sections 105 A-N may only produce 300 Volts of power due to environmental or other conditions.
  • the DC voltage provided by converters 220 A-N can be regulated at approximately 600 Volts and near the maximum power operating point for solar array sections 205 A-N.
  • the current provided to DC-to-AC inverter 225 via wiring 226 can be reduced by a factor of two. Consequently, the efficiency of system 200 can be increased because with lower current, there is less power loss associated with wiring 226 .
  • the gauge of wiring 226 can be reduced to accommodate the lower current being supplied. Because the wiring 226 can be very lengthy, reducing the size and cost of the wiring 226 by approximately a factor of two can provide a cost savings.
  • FIG. 2 The example elements of FIG. 2 are shown by way of example, and other system and apparatus embodiments can have fewer or greater numbers of elements, and such elements can be arranged in alternative configurations in accordance with other embodiments of the invention.
  • FIG. 4 illustrates an exemplary method 400 for converting DC power to AC power according to one embodiment of the invention.
  • the method can begin at block 405 where DC power from at least one DC source can be received or otherwise provided.
  • the DC source can include any appropriate DC source including, but not limited to, a battery, a photovoltaic cell, a fuel cell, an array of cells, or the like.
  • the at least one DC source can be associated with a first ground, such as in FIG. 2 , where solar array sections 205 A-N can be associated with an earth ground.
  • Method 400 can continue at block 410 where the DC power provided by the at least one DC source can be conditioned.
  • Conditioning can be provided by one or more DC-to-DC converters, such as converters 220 A-N in FIG. 2 .
  • conditioning can comprise regulating the DC power being provided by the DC power source, such as with a switching type regulator using some form of pulse width modulation control.
  • conditioning can include boosting the DC power provided by the DC power source from a first voltage to a second voltage, such as with a step up converter or boost converter.
  • conditioning can comprise adjusting the DC power source, or a plurality of DC power sources, to operate at a maximum power point.
  • conditioning can comprise adjusting a plurality of DC power sources, via a plurality of DC-to-DC converters, to operate at their maximum power point.
  • the plurality of DC-to-DC converters can be electrically coupled in parallel with each other and electrically coupled in series with at least one DC-to-AC inverter, such as displayed in exemplary system 200 .
  • Coupled to the plurality of DC-to-DC converters can be one or more controllers, such as controllers 230 A-N.
  • the controllers can be operable to adjust the DC power source to its maximum power point, such as by adjusting at least one characteristic of the DC-to-DC converter.
  • method 400 can progress to block 415 where the conditioned DC power can be isolated from the first ground associated with the at least one DC source. Isolating the conditioned DC power from the first ground associated with at least one DC source can be provided by an isolation transformer.
  • the isolation transformer can be adapted to operate at a high frequency greater than 60 Hz.
  • the isolation transformer can be coupled to a DC-to-DC converter.
  • the isolation transformer can be adapted as part of a DC-to-DC converter.
  • method 400 can proceed by converting the conditioned DC power to AC power.
  • the converted AC power being isolated from the first ground associated with the at least one DC source, can be associated with a second ground.
  • this second ground can be an AC ground associated with a load, such as utility power grid 110 in FIG. 1 .
  • converting the conditioned DC power to AC power at block 420 can be provided by DC-to-AC inverter 225 in FIG. 2 .
  • Method 400 continues to block 425 where the converted AC power can be provided to a least one load. While the preceding discussion has referenced the load as being associated with utility power grid 210 , it will be appreciated that other types of loads can also be provided power. Exemplary loads can include switches, power inverters, motors, and the like.
  • FIG. 4 The example elements of FIG. 4 are shown by way of example, and other process embodiments can have fewer or greater numbers of elements, and such elements can be arranged in alternative configurations in accordance with other embodiments of the invention.

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US12/505,858 US8358033B2 (en) 2009-07-20 2009-07-20 Systems, methods, and apparatus for converting DC power to AC power
AU2010202922A AU2010202922A1 (en) 2009-07-20 2010-07-09 Systems, methods, and apparatus for converting DC power to AC power
EP20100169390 EP2278697A1 (en) 2009-07-20 2010-07-13 Systems, methods, and apparatus for converting DC power to AC power
CN2010102408591A CN101958658A (zh) 2009-07-20 2010-07-20 用于将dc功率转换到ac功率的系统、方法和设备

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